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Old 10-14-2010, 08:53 PM   #1
Tbird Man
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Join Date: Oct 2004
Vehicle:
1999 Legacy GT Ltd.
White

Default Lightweight Pulley Issue?

Ok, I bought my 1999 Leg GT Limited (Ph I 2.5) and could seriously kick the last owner in the head. Among the many issues he left the car with was an improperly tightened Agency Power crank pulley. The bolt had backed off and the pulley was wobbling. I pulled everything off and the woodruff key is almost sheared off right after the timing gear. fortunately the timing gear doesn't seem to have been affected. I had to drive the car 800mi the next day so I put it back together and tightened the bolt down solidly, the pulley still wobbles slightly but it is still tight, how urgent is it that I replace the key? I really don't want to tear into it just yet since i know ill have to pull the timing gear too, but I don't want the pulley to come loose or damage my crank.
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Old 10-15-2010, 08:48 AM   #2
treksofar
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Location: West Boylston, MA
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if the key is sheared to the point where it's not fully engaging with the pulley, then you run the risk of damaging the notch on the pulley where it sits in. if that happens then, even if you repace the key, the extra play will probably shear the new key as well. you can check for this when you get a new key ($4 from the dealer if i remember correctly) by fitting it in the keyway on the pulley. the clearence should be extremely tight. if you notice any burs/gaps or widening of the keyway then chuck the pulley and get a new one. i wouldn let it go for too long since the key also keeps the timing gear in check as well. if that goes then you risk serious engine dammage.
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Old 10-15-2010, 12:43 PM   #3
iluvdrt
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Location: DRTY Autosports Denver, Co
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2012 outback 2.5
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I would fix it ASAP! Not to mention all the additional vibrations occuring to the crank. You could also score the crank snout which can cause problems, hurt the t-belt cover, t-belt, any number of things really.. It needs fixed right away.
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Old 10-15-2010, 04:58 PM   #4
Storm
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96L Most Over-
Developed Beater

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The pulley is likely junk now. Aluminum is softer than steel....and although it messed up the key, the pulley is no longer round inside. The key runs back through the timing gear too, so you'll have to get creative in removing the damaged part so you can remove the timing gear and then replace the key. Carefully dremel the key back into shape (even if smaller) and try not to touch the crank if you can help it. Once you get it to a point where the timing gear will slide off, replace the key and put the timing gear back on. Put a known good crank pulley on and you should be fine for the forseeable future.

Jay
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Old 10-16-2010, 12:18 AM   #5
Tbird Man
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So i will need to take the timing belt off, crap. I really didn't want to get that involved, but i guess you gotta do what you gotta do. Obviously Ill be replacing the timing belt while I am in there, I know most say to replace the water pump, but I really don't have the money for that. what else is absolutely necessary?
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Old 10-17-2010, 12:27 PM   #6
Storm
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Yes, the belt will have to come off in order to remove the timing gear and replace the key in the crank.

Anything else you decide to do at the same time is up to you.

Jay
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Old 10-17-2010, 01:30 PM   #7
LetItSnow
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The water pump isn't very expensive, and when you consider the amount of work it takes to get to it, you'll probably be glad you did it as preventative maintenance.
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